energies

Article
Analysis and Disposal of Typical Breakdown Failure
for Resin Impregnated Paper Bushing in the Valve
Side of HVDC Converter Transformer
Hao Tang 1,2, *, Guangning Wu 1 , Ming Chen 3 , Jiang Deng 1 and Xining Li 2
1 College of Electrical Engineering, Southwest Jiaotong University, Chengdu 611756, China;
gnwu@home.swjtu.edu.cn (G.W.); swjtu_dj@163.com (J.D.)
2 China Electric Power Research Institute, Beijing 100192, China; dalianlxn@163.com
3 State Key Lab. of Electrical Insulation and Power Equipment, Xi’an Jiaotong University, Xi’an 710049, China;
18102336633@163.com
* Correspondence: haotang@163.com or tanghao@epri.sgcc.com.cn; Tel.: +86-18618192151




Received: 5 October 2019; Accepted: 31 October 2019; Published: 12 November 2019


Abstract: This paper presents analysis, diagnosis and disposal with a typical internal breakdown
failure of the resin impregnated paper (RIP) valve side bushing in high voltage direct current (HVDC)
converter transformer. Based on the analysis of fault current characteristics at the time of the RIP
valve side bushing failure, and field test results of insulation parameters, a method of diagnosing
typical breakdown failures of valve side bushings is proposed. Through disassembly inspection of the
internal overheating and arcing traces on the failure bushing, the root cause of this typical breakdown
failure is found, which is upper axial flashover along the RIP condenser/SF6 interface caused by the
abnormal contact of two current-carrying conductive tubes. Temperature distribution inside the
bushing with an abnormal contact resistance between the copper conductive tube and aluminum
conductive tube under different load current is simulated by using the finite element method. An
special device is also developed for repairing defective bushing on-site, and 75 bushings with
conductive contact defects have been repaired on the premise of not pushing converter transformers
away from the valve hall and even without pulling out defective bushings.

Keywords: valve side bushing; resin impregnated paper; HVDC converter transformer; bushing
breakdown failure; field repair

1. Introduction
In the HVDC converter station, the bushing of valve side winding (valve side bushing) is the key
high voltage component of the HVDC converter transformer, and its reliability is directly related to the
operation safety of the converter transformer and AC/DC hybrid power grid. During operation, the
ambient temperature of the valve side bushing is high, and its current-carrying central tube carries a
large harmonic current component, in addition to the fundamental current. Affected by the harmonic
current skin effect, the valve side bushing with insufficient current capacity is prone to insulation
failure, which is caused by overheating inside bushing during the highest load period [1–9]. In recent
years, Yimin, Baoji, Fengjing etc. HVDC converter stations in China have repeatedly experienced
internal breakdown failures on resin impregnated paper (RIP) valve side bushing caused by current
heating, resulting in single-pole lockout at the HVDC converter stations, which has large negative
impact on the AC-DC transmission system [10–14].
The main insulation of the RIP valve side bushing used in HVDC transmission project in China is
resin impregnated paper condenser, and its upper envelope is a composite hollow insulator. The space
between the condenser and the upper envelope is filled with SF6 . The condenser of this RIP bushing

Energies 2019, 12, 4303; doi:10.3390/en12224303 www.mdpi.com/journal/energies

Energies 2019, 12, 4303 2 of 13
Energies 2019, 12, x FOR PEER REVIEW 2 of 13

has poor thermal

bushing has poorconductivity, and most ofand
thermal conductivity, the heat
mostinside
of thethe bushing
heat insidecan theonly be transmitted
bushing can onlythrough
be
transmitted
the through the central
central current-carrying current-carrying
conductive tube. It isconductive
easy to cause tube. It is overheating
partial easy to cause partial
defects inside
overheating defects inside the bushing under high ambient temperature
the bushing under high ambient temperature and high-load current operating conditions. Increasing and high-load current
operating
the diameter conditions. Increasing the
and cross-sectional areadiameter and cross-sectional
of the current-carrying area of tube
conductive the current-carrying
and using the heat
conductive
pipe tube are
technology andeffective
using the heat pipe
methods technology
to solve are effective
the internal overheatingmethods to solve
problems the internal
[15–18]. However,
overheating problems [15–18]. However, bushing with a larger diameter conductive
bushing with a larger diameter conductive tube will have a higher economic cost and a more complex tube will have a
higher economic cost and a more complex structure. Meanwhile the heat pipe
structure. Meanwhile the heat pipe technology needs to solve the problem of liquid-gas mixed material technology needs to
solve the problem of liquid-gas mixed material sealing and long-term stability. IEC 60137 standard
sealing and long-term stability. IEC 60137 standard specifies the calculation method for the hot spot
specifies the calculation method for the hot spot temperature of conventional HVAC bushings.
temperature of conventional HVAC bushings. However, the current-carrying connection structure and
However, the current-carrying connection structure and operating conditions of the RIP valve side
operating conditions of the RIP valve side bushing are different from those of HVAC bushings, and
bushing are different from those of HVAC bushings, and there is a big difference between the
there is a big difference between the calculation result of the hot spot temperature value and the actual
calculation result of the hot spot temperature value and the actual value [19–21]. Despite having
value [19–21]. Despite having passed the temperature rise test, internal breakdown failures of RIP
passed the temperature rise test, internal breakdown failures of RIP valve side bushings, caused by
valve side bushings,
overheating caused by
under long-term overheating
load undermight
current [22–24], long-term load current [22–24], might still happen.
still happen.
In
In this
thispaper,
paper,a typical
a typicalinternal breakdown
internal breakdown failure of RIP
failure of valve side bushing
RIP valve causedcaused
side bushing by the overheating
by the
of the copper–aluminum conductive tube transition joint at ± 500 kV Baoji
overheating of the copper–aluminum conductive tube transition joint at ± 500 kV Baoji converter converter station is analyzed.
A method
station to diagnose
is analyzed. four typical
A method breakdown
to diagnose failures,breakdown
four typical a simulation calculation
failures, methodcalculation
a simulation to analyze the
temperature distribution
method to analyze of abnormal
the temperature overheating
distribution bushing, and
of abnormal an on-site
overheating disposal
bushing, anddevice to repair
an on-site
defective bushings are put forward. These methods can be used to diagnose
disposal device to repair defective bushings are put forward. These methods can be used to diagnose RIP valve side bushing
failures,
RIP valveevaluate how much
side bushing load current
failures, a defective
evaluate how much bushing
loadcan run safely
current and howbushing
a defective to repaircan
the defective
run
bushings
safely and at how
the lowest economic
to repair cost on the
the defective premise
bushings atof ensuring
the lowest the safety of
economic theon
cost converter transformer.
the premise of
ensuring the safety of the converter transformer.
2. Structure of the Failed RIP Valve Side Bushing
2. Structure of the Failed
From September 2015RIP Valve
to June Sideseveral
2019, Bushing± 500 kV RIP valve side bushings from Yimin converter
station,
FromTuanlin converter
September station
2015 to June and
2019,Fengjing
several ±converter
500 kV RIP station
valvewere
side found to from
bushings have Yimin
abnormal
overheating defects.
converter station, Meanwhile,
Tuanlin one ±
converter 500 kV
station RIPFengjing
and valve side bushingstation
converter in Baojiwere
converter
found station
to havebroke
abnormal
down overheating
on April defects.
16, 2017. Meanwhile,
The insulation one ± 500
structure andkVcurrent-carrying
RIP valve side bushing in Baoji
connection converter
structure of these
stationvalve
failed broke down
side on April
bushings 16, 2017.
is shown The insulation
in Figure 1. structure and current-carrying connection
structure of these failed valve side bushings is shown in Figure 1.

(a) Insulation structure (b) Current-carrying connection structure

Figure
Figure1.1.Structure
Structureofofthe
thefailed resin
failed impregnated
resin paper
impregnated (RIP)
paper valve
(RIP) sideside
valve bushings.
bushings.
Energies2019,
Energies 12,x4303
2019,12, FOR PEER REVIEW 3 3ofof13
13

All these bushings have the same insulation and current-carrying connection structure. This
All these bushings have the same insulation and current-carrying connection structure. This
paper takes the failed bushing of the Baoji converter station as an example to analyze characteristics
paper takes the failed bushing of the Baoji converter station as an example to analyze characteristics
and the root cause of this breakdown failure.
and the root cause of this breakdown failure.
The external envelope of the failed bushing is a composite hollow insulator, and its inner
The external envelope of the failed bushing is a composite hollow insulator, and its inner insulation
insulation is resin impregnated paper condenser body. The space inbetween the insulator and
is resin impregnated paper condenser body. The space inbetween the insulator and condenser is filled
condenser is filled with SF6. Foil layers arranged inside the RIP condenser can control both axial and
with SF6 . Foil layers arranged inside the RIP condenser can control both axial and radial electric
radial electric field inside the bushing, and as well to adjust external electric field outside the envelope
field inside the bushing, and as well to adjust external electric field outside the envelope insulator.
insulator. DC-bandages are designed on the upper and lower surface of RIP condenser to release the
DC-bandages are designed on the upper and lower surface of RIP condenser to release the surface
surface charge. Inside the RIP condenser of the failed bushing is designed by a double-tube structure.
charge. Inside the RIP condenser of the failed bushing is designed by a double-tube structure. The
The outer tube is an aluminum alloy tube, which is used to winding the condenser body but does not
outer tube is an aluminum alloy tube, which is used to winding the condenser body but does not carry
carry any current. The inner central tube is a copper current-carrying conductive tube. Outside the
any current. The inner central tube is a copper current-carrying conductive tube. Outside the upper
upper part of RIP condenser body, the inner copper conductive tube and another aluminum
part of RIP condenser body, the inner copper conductive tube and another aluminum conductive tube
conductive tube form a copper–aluminum transition joint through spring contact, which can offset
form a copper–aluminum transition joint through spring contact, which can offset relative displacement
relative displacement of the insulator and conductor when temperature changes.
of the insulator and conductor when temperature changes.

3.Characteristics
3. and Diagnosis
Characteristics and Diagnosisof
ofthe
theFailure
Failure
Baoji converter station
Baoji converter stationuses
usesa typical
a typical 12-pulse
12-pulse converter
converter systemsystem consisting
consisting of twoof two six-pulse
six-pulse rectifier
rectifier bridges in series, three Y/Y converter transformers and three Y/D converter transformers,
bridges in series, three Y/Y converter transformers and three Y/D converter transformers, 12 valve side 12
valve side bushings. Each converter transformer has an end valve side bushing and a
bushings. Each converter transformer has an end valve side bushing and a top valve side bushing,top valve side
bushing,
which arewhich are connected
connected to of
to terminals terminals
the valveofside
the winding
valve side
of winding of transformer.
transformer. Fault currentFault current
waveform at
waveform at the time of the RIP valve side bushing failure, and the insulation characteristic
the time of the RIP valve side bushing failure, and the insulation characteristic parameters after the
parameters
failure wereafter the failure
measured were
for the measured
purpose for the purpose
of analyzing the rootof analyzing the root causes.
causes.

3.1.
3.1.Fault
FaultCurrent
CurrentWaves
Wavesand
andLoop
Loop
At
At the
the time
time of of the
the RIP RIP valve
valve side
side bushing
bushing failure,
failure, valvevalve sideside line
line current
current of of Y/Y
Y/Y converter
converter
transformer
transformer(I(IY-A , I
, I
Y-B ,
Y-A Y-B Y-C
I , I
Y-C ) and
) those
and of
those Y/D
of converter
Y/D convertertransformer
transformer (I D-A,(I
I D-B, ,ID-C
I
D-A D-B D-C
) are
, I shown
) are in Figure
shown in
2a,b. The peak value of fault current which is defined as I , and it is equal
Figure 2a,b. The peak value of fault current which is defined as IF , and it is equal to IY-B , ID-B , ID-C .
F to I Y-B, I D-B , I D-C . These fault
current are all
These fault 10 kA,are
current shown
all 10inkA,Figure 2a. Iin
shown , IY-C, ID-A
Y-AFigure areIY-A
2a. close to, 0ID-A
, IY-C A. Meanwhile,
are close to 0asA. shown in Figure
Meanwhile, as
3, the current in the pole line (I ) is also 0 A, while the current in the neutral
shown in Figure 3, the current in the pole line (IDP ) is also 0 A, while the current in the neutral line
DP line (I DNC ) is equal to 10
kA. The
(IDNC ) iswhole
equal duration
to 10 kA. time of faultduration
The whole current timeis about 10 ms,
of fault in the
current is meantime,
about 10 ms, Y rectifier bridge V6Y
in the meantime,
and D rectifier
rectifier bridgebridge
V6 andV5 D and V6 turn
rectifier on.V5 and V6 turn on.
bridge

(a) Valve side line current of Y/Y (b) Valve side line current of Y/D

Faultcurrent
Figure2.2.Fault
Figure currentwaves
wavesin
inall
allvalve
valveside
sideof
ofconverter
convertertransformers.
transformers.

Based on the characteristics of these currents, the flow loop of the fault current in the
converter station can be obtained, shown in Figure 3. The location of the fault current entering the
Energies 2019, 12, x FOR PEER REVIEW 4 of 13

earth can be concluded at the end valve side of Y/Y-B converter transformer. This shows that the end
Energies 12, 4303
2019,bushing
valve side of Y/Y-B converter transformer has been broken down. 4 of 13

Figure 3. Fault current loop in converter station at the time of bushing failure.
Figure 3. Fault current loop in converter station at the time of bushing failure.
Based on the characteristics of these currents, the flow loop of the fault current in the converter
3.2. Insulation
station can be Characteristics
obtained, shownafterinFailure
Figure 3. The location of the fault current entering the earth can be
concluded at the
Field test end valve
results side of Y/Y-B
of insulation converter on
characteristics transformer. This shows
bushings after failure that
are the endin
shown valve side
Table 1,
bushing of Y/Y-B converter transformer has been broken down.
including the main insulation resistance, test tap insulation resistance, capacitance, dielectric loss
factor (tanδ), decomposition gas SO2 and H2S on both the top and the end valve side bushings of Y/Y
3.2. Insulation Characteristics after Failure
converter transformers in phase A, B and C. Meanwhile, an oil sample was also taken from the
Field transformers,
converter test results ofand insulation
the DGAcharacteristics
result including onCbushings
2H2, H2 and after failure
total are shown
hydrocarbon in showed
is also Table 1,
including
in Table 1.the
DL/T main insulation
393-2010 resistance,
standard test values
specifies tap insulation
of theseresistance,
insulationcapacitance,
characteristics.dielectric loss
factor (tanδ), decomposition gas SO2 and H2 S on both the top and the end valve side bushings of
Table 1. transformers
Y/Y converter Field test results
inofphase
insulation
A, B characteristics related to
and C. Meanwhile, antransformer
oil samplevalve side bushings.
was also taken from the
converter transformers, and the DGA result including C2 H2 , H2 and total hydrocarbon is also showed
Standard Y/Y-A Y/Y-B Y/Y-C
in TableTest Item 393-2010 standard specifies values of these insulation characteristics.
1. DL/T
Value Top End Top End Top End
CTable
2H2 (µL/L)
1. Field test results≤of1 insulation characteristics
0.0 0.0
related to transformer 0.0
valve side bushings.
H2 (µL/L) ≤ 150 4.2 3.1 3.8
Total hydrocarbon Y/Y-A Y/Y-B Y/Y-C
Test Item ≤ 150 Standard Value
8.5 9.4 9.0
(µL/L) Top End Top End Top End
Main insulation
C2 H2 (µL/L) ≤1
≥ 10,000 50,000 50,000 0.050,000 0.0
140 50,000 0.0 50,000
resistance (MΩ)
H2 (µL/L) ≤ 150 4.2 3.1 3.8
Total hydrocarbon
Test tap insulation (µL/L) ≤ 150 8.5 9.4 9.0
Main insulation resistance≥(MΩ) 1000 10,000
≥ 10,000 10,000
50,000 10,000
50,000 50,000 0.1 140 10,000 10,000
50,000 50,000
resistance (MΩ)
Test tap insulation resistance (MΩ) ≥ 1000 10,000 10,000 10,000 0.1 10,000 10,000
Capacitance (pF) (pF)1200 ± 5%
Capacitance 1192
1200 ± 5% 1192
1192 1188
1192 1188- - 1161
1161 1160
1160
Dielectric loss
Dielectric factor
loss factor (tanδ (%)) < 0.7 0.33 0.35 0.30 - 0.32 0.32
< 0.7 0.33 0.35 0.30 - 0.32 0.32
(tanδ (%))
SO2 (µL/L) ≤2 0 0 0 150 0 0
SO2 (µL/L)H2 S (µL/L) ≤2 ≤
02 00 00 0 150 0 00 0 0
H2S (µL/L) ≤2 0 0 0 0 0 0
Field test results of insulation characteristics in Table 1 shows that the main insulation resistance
of theField
end test
valveresults
side of insulation
bushing characteristics
for Y/Y-B converterintransformer
Table 1 shows that140
is just the MΩ,
mainwhile
insulation resistance
that of test tap
of the end resistance
insulation valve sideisbushing
close tofor Y/Y-B converter
0. What’s more, testtransformer
voltage cannotis justbe140 MΩ, on
applied whilethethat of testthus
bushing, tap
insulation resistance
capacitance and tanδiscannot
close to be0.tested,
What’s more,indicates
which test voltage
that cannot
internalbebreakdown
applied onoccurs
the bushing,
on the thus
RIP
capacitancebetween
condenser and tanδ thecannot be tested,tube
HV conductive whichandindicates that internal
the intermediate breakdown
flange, occurs onisthe
and the insulation RIP
totally
damaged. SO2 was also detected inside the composite hollow insulator, and it can be concluded that
an arcing path is inside the hollow insulator.
Energies 2019, 12, x FOR PEER REVIEW 5 of 13

condenser between the HV conductive tube and the intermediate flange, and the insulation is totally
damaged.
Energies 2019,SO was
also detected inside the composite hollow insulator, and it can be concluded5 that
12,24303 of 13
an arcing path is inside the hollow insulator.

3.3. Overheating
3.3. Overheating and
and Arcing
Arcing Trace
Trace of
of Disassembled
Disassembled Bushing
Bushing
After removing
After removing the the failed
failed bushing
bushing fromfrom thethe converter
converter transformer,
transformer, dc dc resistance
resistance testtest and
and
disassemble inspection was carried out. The total conductive tube dc resistance of
disassemble inspection was carried out. The total conductive tube dc resistance of the failed bushing the failed bushing is
above
is 1900
above 1900µΩ,µΩ,which
which is ismuch
muchhigher
higherthan
thanthat
thatofofthe
thenormal
normalvalue
value(less
(lessthan
than50 µΩ). Arcing
50 µΩ). Arcing trace
trace
and overheating trace on RIP condenser, intermediate flange and conductor,
and overheating trace on RIP condenser, intermediate flange and conductor, as well as overheating as well as overheating
trace on
trace on current-carrying
current-carrying conductive
conductive tubes
tubes and
and insulating
insulating material,
material, are
are recorded
recorded during each step
during each step of
of
the disassemble
the disassemble process.
process.
The arcing
The arcing and
and overheating
overheatingtraces tracesofofthe
thedisassemble
disassembleinspection
inspectionononthe failed
the failedbushing
bushing is shown
is shown in
Figure 4. When the composite hollow insulator is cut down, obvious overheating
in Figure 4. When the composite hollow insulator is cut down, obvious overheating trace is found on trace is found on
the contact
the contact surface
surface of
of the
the copper–aluminum
copper–aluminum conductive
conductive tubetube transition
transition joint. Inside the
joint. Inside the joint,
joint, partial
partial
contact surface of both copper conductive tube and aluminum conductive
contact surface of both copper conductive tube and aluminum conductive tube has been melt, tube has been melt, andand
the
spring
the contact
spring between
contact two tubes
between twois tubes
totallyisdamaged. Due to overheating,
totally damaged. cracking and cracking
Due to overheating, carbonizationand
of the top RIP condenser close to the transition joint has occurred. Some carbonized
carbonization of the top RIP condenser close to the transition joint has occurred. Some carbonized decomposition
particles are attached
decomposition to the
particles are top-part
attachedsurface of RIP condenser.
to the top-part surface of RIP condenser.

Figure 4. Arcing
Arcing and
and overheating
overheating trace detected on the RIP condenser and conductive tube.

There is a clear axial arcing trace on the surface of RIP condenser,

condenser, which starts from the top-part
surface of RIP condenser close to the high voltage conductive tube to the DC bandage which is
grounded to the earth. All these overheating and arcing trace indicate that there is an axial flashover
along the
the RIP
RIP condenser/SF
condenser/SF66interface.
interface.Axial
Axialflashover
flashoverarcing
arcing path
path ofof the
the failed
failed bushing
bushing is showed
is showed in
in Figure
Figure 5. 5.
TheThe arcing
arcing path
path starts
starts from
from thecopper
the coppershield
shieldofofconductive
conductivetubetubeatatthe
the top
top of
of the RIP
condenser, along the interface of the RIP condenser
condenser and SF SF66, after passing through the DC bandage
and finally enter the earth through the test tap and intermediate
intermediate flange.
flange.
It was clear that the solid insulator material (resin impregnated paper) around area of the
copper–aluminum transition joint has been carbonized due to the overheating of high abnormal
contact resistance at the copper–aluminum conductive tube transition joint. These carbonation
Energies 2019, 12, x FOR PEER REVIEW 6 of 13

decomposition particles are attached to the surface of RIP condenser which can lead to a reduction in
the flashover voltage. Influence of partial overheating of abnormal copper–aluminum transition joint
Energies 2019, 12, 4303 6 of 13
inside bushing on abnormal temperature distribution is analyzed in Section 4.

Figure 5. Axial arcing path along the condenser/SF6 interface of the failed bushing.
Figure 5. Axial arcing path along the condenser/SF6 interface of the failed bushing.
It was clear that the solid insulator material (resin impregnated paper) around area of the
3.4. Typical Breakdown
copper–aluminum Failures
transition Diagnosis
joint has been carbonized due to the overheating of high abnormal contact
resistance
When analyzing the failures ofconductive
at the copper–aluminum tube
the valve side transitionthe
bushings, joint. Thesewhere
location carbonation
the faultdecomposition
current flows
particles are attached
into the earth to the surface
can be concluded of RIP
by the condenser
magnitude andwhich can of
direction lead
thetofault
a reduction flashover
current in the converter
voltage. Influence of partial overheating of abnormal copper–aluminum transition joint inside
station and the characteristics of the fault current flow loop. Through the multiple external features bushing
on abnormal
of the temperature
valve side distribution
bushing where is current
the fault analyzed in Section
enters 4. including external visual inspection
the earth,
of arcing traces, the capacitance and insulation resistance of the bushing condenser, the
3.4. Typical Breakdown Failures Diagnosis
decomposition gases of SF6, and the dissolved gas of converter transformer oil, the types of
breakdown inside or outside
When analyzing valve
the failures of side bushing
the valve sidecan be deduced.
bushings, the location where the fault current flows
Forearth
into the the failed
can beRIP valve side
concluded bybushing of Baoji and
the magnitude converter station,
direction there
of the faultiscurrent
no arcing trace
in the outside
converter
the composite
station and thehollow insulator
characteristics of and the DGA
the fault result
current flowofloop.
transformer
Throughoiltheis multiple
normal. However, the main
external features of
insulation
the resistance,
valve side bushingthe capacitance
where the fault and theenters
current dielectric loss factor
the earth, of theexternal
including bushing are all
visual abnormal,
inspection of
and large
arcing amount
traces, of SO2 gas and
the capacitance frominsulation
SF6 decomposition
resistance of is also detectedcondenser,
the bushing inside thethecomposite hollow
decomposition
gases of SFBased
insulator. 6 , and on
the all these
dissolved test results,
gas of the
converter type of bushing
transformer oil,failure
the typescan be
of diagnosed
breakdown as
inside or
axial
outside valve side bushing can be deduced.
flashover along the condenser/SF6 interface.
For the failed
According to RIP
fourvalve side bushing
characteristics of of BaojiRIP
failed converter
valve sidestation, there and
bushing is noits
arcing trace
related outside
converter
the composite hollow insulator and the DGA result of transformer oil is normal.
transformer, which include external arcing traces of the bushing air-side, dissolved gas analysis However, the main
insulation
results (DGA)resistance, the capacitance
of converter and theoil,
transformer dielectric loss factor
capacitance andof insulation
the bushingcharacteristics
are all abnormal, of
and large amount of SO gas from SF decomposition is also detected
bushing’s condenser, decomposition gases of SF6 inside the bushing’s composite hollow
2 6 inside the composite hollow
insulator.
insulator,Based
four on all these
typical test results,failures
breakdown the typeand
of bushing failure canmethod
their diagnosis be diagnosed as axial flashover
are proposed. These
along the condenser/SF6 interface.
breakdown failures are flashover outside the air-side of the composite hollow insulator, axial
According to four characteristics of failed RIP valve side bushing and its related converter
transformer, which include external arcing traces of the bushing air-side, dissolved gas analysis results
(DGA) of converter transformer oil, capacitance and insulation characteristics of bushing’s condenser,
Energies 2019, 12, 4303 7 of 13

Energies 2019, 12, x FOR PEER REVIEW 7 of 13

decomposition gases of SF6 inside the bushing’s composite hollow insulator, four typical breakdown
failures and
flashover theirthe
along diagnosis method are proposed.
RIP condenser/SF These breakdown failures are flashover outside the
6 interface, radial puncture inside the RIP condenser, and
air-side of the composite hollow insulator, axial flashover along the RIP condenser/SF interface, radial
oil-side puncture from conductive tube to the bushing turret. The diagnosis flow6 chart is shown
puncture inside the RIP condenser, and oil-side puncture from conductive tube to the bushing turret.
in Figure 6. Some more cases of breakdown bushings indicate that a defect caused by axial
The diagnosis flow chart is shown in Figure 6. Some more cases of breakdown bushings indicate that a
flashover along the condenser/SF6 interface is generally accompanied by large amount of SO2,
defect caused by axial flashover along the condenser/SF6 interface is generally accompanied by large
and the recommended concentration of this gas is greater than 100 µL/L. While a defect caused
amount of SO2 , and the recommended concentration of this gas is greater than 100 µL/L. While a
by radial puncture inside the condenser body of bushing is usually accompanied by tiny amount
defect caused by radial puncture inside the condenser body of bushing is usually accompanied by tiny
of SO2, and
amount of SOthe, and
recommended concentration
the recommended of thisofgas
concentration is gas
this undetectable or less
is undetectable or than 5 µL/L.
less than 5 µL/L.
2

Figure 6. Typical breakdown failure diagnosis flow chart.

Figure 6. Typical breakdown failure diagnosis flow chart.
4. Temperature Simulation and Analysis on the Failed Bushing
4. Temperature Simulation
In normal condition, and
the DCAnalysis onRthe
resistance Failed Bushing
0 of failed bushing in Baoji converter station is 35 µΩ,
but for
In the failedcondition,
normal state, it isthe
1900
DCµΩ, of whichR1855
resistance µΩ is the resistance of the spring contact transition
0 of failed bushing in Baoji converter station is 35 µΩ,
joint between the copper and aluminum conductive
but for the failed state, it is 1900 µΩ, of which 1855 µΩ tubes.
is theThe causes of
resistance of the
abnormal contact transition
spring contact resistance
include
joint the non-concentric
between the copper installation of the conductive
and aluminum copper–aluminumtubes. conductive
The causestube, insufficient contact
of abnormal contact
resistance include the non-concentric installation of the copper–aluminum conductive tube,
insufficient contact area between copper–aluminum tubes with spring contact finger, as well as
improper treatment of silver plating on contact surface.
Energies 2019, 12, 4303 8 of 13

area between copper–aluminum tubes with spring contact finger, as well as improper treatment of
silver plating on contact surface.
Energies 2019, 12, x FOR PEER REVIEW 8 of 13
In order to analyze the influence internal temperature distribution of the abnormal contact
resistance undertovarious
In order analyzeload
thecurrent,
influencetheinternal
total normal resistance
temperature loss and of
distribution thethe
total abnormal
abnormal contact
contact
resistance
resistance under various load current, the total normal resistance loss and the total abnormal contactp.u.
loss of the copper–aluminum transition joint at 0.25 p.u., 0.50 p.u., 0.75 p.u. and 1.00
load current loss
resistance are calculated respectively. Considering
of the copper–aluminum transition joint theatmainly
0.25 p.u.,harmonic
0.50 p.u., number
0.75 p.u.h isand
1, 5,
1.007, 11p.u.and
13,load
the current are calculated
corresponding respectively.
resistance loss PR0_hConsidering
and PRc_h the are mainly
calculated harmonic number
and shown inhTable
is 1, 5,2.7,P111 , and
P 2 , P3 ,
and P4 which are consist of Σ(PR0_h ) and Σ(PRc_h ) represent the total resistance loss of all harmonic
13, the corresponding resistance loss P R0_h and PRc_h are calculated and shown in Table 2. P 1, P 2, P 3 , and
P4 which
current are consist
resistances of Σ(P
at load R0_h) andof
currents Σ(P0.25 ) represent
Rc_hp.u., 0.5 p.u., the0.75
totalp.u..
resistance lossp.u..
Also, 1.0 of allPharmonic
R0_h is thecurrent
heat loss
of resistances at load currents
a single harmonic currentofwith0.25ap.u., 0.5p.u.,
normal DC0.75 p.u.. Also,
resistance R0 ,1.0
while R0_h is
p.u..PPRc_h isthe
theheat
heatloss
lossofofa single
a single
harmonic current with a normal DC resistance R , while P
harmonic current with abnormal contact resistance, and h can be 1, 5, 7, 11, or 13.
0 Rc_h is the heat loss of a single harmonic
current with abnormal contact resistance, and h can be 1, 5, 7, 11, or 13.
Table 2. Calculated resistance loss under different load current related with the current spectrum.
Table 2. Calculated resistance loss under different load current related with the current spectrum.
Harmonic Current P1 /W(0.25 Ih ) P2 /W(0.50 Ih ) P3 /W(0.75 Ih ) P4 /W(1.0 Ih )
Frequency/Hz
Harmonic Ih /A P1/W(0.25 Ih)
PRc_h P2P /W(0.50 IPhRc_h
) PP3/W(0.75 PIRc_h
h) PP4R0_h
/W(1.0 PIhRc_h
)
Number/h
Frequency Current PR0_h R0_h R0_h
Number/
1 /Hz50 Ih /A2299 PR0_h 23.2 PRc_h1230.0 PR0_h 92.8 P4919.8
Rc_h 208.9 P11069.5
PR0_h Rc_h 371.3 P19679.1
PR0_h Rc_h
h
5 250 414 1.6 86.0 6.5 344.0 14.6 774.1 26.0 1376.1
1 50 2299 23.2 1230.0 92.8 4919.8 208.9 11069.5 371.3 19679.1
7 350 247 0.7 36.2 2.7 144.9 6.2 326.0 10.9 579.6
5 250 414 1.6 86.0 6.5 344.0 14.6 774.1 26.0 1376.1
11 550 99 0.1 7.3 0.6 29.2 1.2 65.7 2.2 116.7
7 350 247 0.7 36.2 2.7 144.9 6.2 326.0 10.9 579.6
13 650 59 0.1 2.8 0.2 11.3 0.5 25.4 0.9 45.1
11 550 99 0.1 7.3 0.6 29.2 1.2 65.7 2.2 116.7
Total resistance loss 25.7 1362.3 102.8 5449.2 231.3 12260.6 411.3 21796.6
13 650 59 0.1 2.8 0.2 11.3 0.5 25.4 0.9 45.1
Total resistance loss 25.7 1362.3 102.8 5449.2 231.3 12260.6 411.3 21796.6
The finite element simulation model with an abnormal contact resistance between the copper
The finite
conductive tube andelement simulation
aluminum model tube
conductive withisan abnormal contact
established. According resistance
to Table between the resistance
2, the total copper
loss Σ(PR0_h +Ptube
conductive Rc_h ) and
of aluminum
the load conductive
current of 0.25 tube
p.u., is
0.5 established.
p.u., 0.75 p.u.,According
1.0 p.u. isto Table
applied 2,
to the
the total
bushing
resistance loss Σ(P +P ) of the load current of 0.25 p.u., 0.5 p.u., 0.75
model, and the simulation result of the internal temperature distribution of the bushing is shown
R0_h Rc_h p.u., 1.0 p.u. is applied to the in
Figure 7. In the simulation model, the temperature in the valve side bushing oil is set to 70 C, andisthe
bushing model, and the simulation result of the internal temperature distribution of the bushing
◦
showntemperature
ambient in Figure 7. In of the
the simulation model,
air side is set to 40the
◦ C.temperature in the valve side bushing oil is set to
70 °C, and the ambient temperature of the air side is set to 40 °C.

Figure7.7.The
Figure The temperature distributionunder
temperature distribution underdifferent
differentload
loadcurrent.
current.

Temperature curves along the surface of the composite hollow insulator from point A to point
B outside the bushing, and temperature curves along the surface of the copper–aluminum conductive
Energies 2019, 12, 4303 9 of 13

Temperature curves along the surface of the composite hollow insulator from point A to point B
outside
Energies the12,
2019, bushing, and
x FOR PEER temperature
REVIEW curves along the surface of the copper–aluminum conductive 9 of 13
tube inside the bushing are shown in Figure 8. The four points A, B, C and D are indicated in
tube inside
Figure the bushing
5. These are shown
temperature curvesin Figuresimulation
include 8. The fourresults
pointsunder
A, B, 1.0
C and
p.u.Dload
are current
indicated in Figure
with normal
5.conductive
These temperature
resistance,curves
as wellinclude
as undersimulation
0.25 p.u., results under
0.50 p.u., 1.0 p.u.
0.75 p.u., andload current
1.0 p.u. loadwith normal
current with
conductive resistance, as well as under 0.25 p.u., 0.50p.u., 0.75 p.u.,
abnormal contact resistance between the copper and aluminum conductive tubes.and 1.0 p.u. load current with
abnormal contact resistance between the copper and aluminum conductive tubes.

(a) Surface of composite hollow insulator (b) Surface of the conductive tube
Temperatureoutside
Figure8.8.Temperature
Figure outsideand
andinside
insidethe
thefailed
failedbushing
bushingunder
underdifferent
differentload
loadcurrent.
current.

ItItcan
canbebeseen
seen from
from Figure
Figure 88 that
that when
when the
the copper–aluminum
copper–aluminumtransitiontransitionjoint
jointofofthethebushing
bushingisis
normal (Rc = 0), the surface temperature of the insulator is 40 ◦ C under rated load current (1.0 p.u.
normal (Rc = 0), the surface temperature of the insulator is 40 °C under rated load current (1.0 p.u.
normal),and andthethecopper–aluminum
copper–aluminum transition
transition zone
zone temperature
temperature is is also
also 40 ◦ C.
40 °C.
normal),
Whenspring
When springcontact
contactof ofthe
thecopper–aluminum
copper–aluminumconductive
conductivetubetube isis abnormal
abnormal (Rc (Rc ==1855
1855µΩ),
µΩ),thethe
temperature of the silicone rubber insulator reaches 75 ◦ C under the load current of 0.25 p.u., and the
temperature of the silicone rubber insulator reaches 75°C under the load current of 0.25 p.u., and the
temperatureof
temperature ofthe
thetransition
transitionjoint
jointbetween
betweenthethecopper
copperandandaluminum
aluminumconductive
conductivetubes tubes(the(thehighest
highest
point of the purple curve in Figure 8b) reaches more than 150 ◦ C, which is higher than the temperature
point of the purple curve in Figure 8b) reaches more than 150°C, which is higher than the temperature
limit120120°C◦ C specified by IEC standard. Therefore, from the analysis results, it can be seen that the
limit specified by IEC standard. Therefore, from the analysis results, it can be seen that the
maximum safe operation
maximum safe operation current
currentof ofthe
thedefective
defectivebushing
bushingwithwith abnormal
abnormal contact
contact resistance
resistanceis not
is
above 0.25 p.u.
not above 0.25 p.u.
Asthetheload
loadcurrent
currentincreases
increases to
to0.75
0.75p.u.,
p.u.,the
thetemperature
temperature of of the
the transition
transition joint
joint is
is close
close to
to 1000 ◦ C,
1000 °C,
As
atwhich
at which temperature
temperature the thecopper
copperconductor
conductorwillwillbegin
begintoto
melt.
melt.TheThetemperature
temperature at the
at upper part of
the upper the
part
RIP condenser close to the transition joint is also more than 200 ◦ C. Under this extreme condition, partial
of the RIP condenser close to the transition joint is also more than 200 °C. Under this extreme
material of the upper RIP condenser begins to carbonize and decompose. Carbonized decomposition
condition, partial material of the upper RIP condenser begins to carbonize and decompose.
products of solid insulating materials and metal melts can contaminate the interface between the RIP
Carbonized decomposition products of solid insulating materials and metal melts can
condenser body and the SF6 gas, reducing the dielectric strength of bushing and ultimately causing the
contaminate the interface between the RIP condenser body and the SF6 gas, reducing the dielectric
axial flashover along the condenser/SF6 interface.
strength of bushing and ultimately causing the axial flashover along the condenser/SF6 interface.
5. Field Repair of Defective Bushings
5. Field Repair of Defective Bushings
The analysis in this paper shows that the overheating of the copper–aluminum conductive tube
The analysis
transition joint ofin this
the RIP paper
valveshows that the can
side bushing overheating of the
lead to axial copper–aluminum
flashover along the RIP conductive tube
condenser/SF 6
transition joint of the RIP valve side bushing can lead to axial flashover along the RIP
interface. To solve the similar problems of the same type bushing in Yimin converter station, Tuanlin condenser /SF6
interface.
converterTo solveand
station the similar
Fengjingproblems
converter ofstation,
the same type bushing
a special bushing in repair
Yimindevice
converter station, Tuanlin
is developed, which
converter
can be used to repair defective bushings on-site directly without pushing converter transformerswhich
station and Fengjing converter station, a special bushing repair device is developed, away
can
frombethe
used to hall
valve repair
anddefective bushings
without pulling outon-site directly
the bushing without
from pushingtransformer.
the converter converter transformers
The bushing
away from the valve
field repairing devicehall and without
is suitable for all pulling outbushings
valve side the bushing
withfrom thecontact
spring converter
jointtransformer. The
conductive tube.
bushing field repairing device is suitable for all valve side bushings
The structure of the repair device for defective bushings is shown in Figure 9. with spring contact joint
conductive tube. The structure of the repair device for defective bushings is shown in Figure 9.
The bushing field repair device shown in Figure 9 includes lifting platform and power assisting
robot, hydraulic station, laser pointer and bushing fixture respectively mounted on the lifting
platform. The device can be used to quickly and cost-effectively disassemble and assemble the
defective RIP valve side bushing and its composite hollow insulator, as well as accurately control the
Energies 2019, 12, x FOR PEER REVIEW 10 of 13

Energies 2019, 12, 4303

force and distance required to disassemble and install the conductive tube with the help of10the
of 13

assisting robot and laser pointer.

(a) Structure of the repair device

(b) Application of the repair device

(c) Fixture platform of repair device (d) Laser alignment in repair

Figure 9. 9.
Figure Structure and
Structure application
and of of
application thethe
field repair
field device
repair forfor
device defective bushing.
defective bushing.

Theprocedure
The bushing field repair
of field device shown
repairing in Figurecopper–aluminum
for abnormal 9 includes lifting platform andtube
conductive power assisting
transition
robot,
joints onhydraulic
defectivestation,
bushings laser pointerpre-treatment,
includes and bushing fixture
bushing respectively
and repairmounted on the lifting
device positioning, topplatform.
cover
The device
removal, caninspection
defect be used toand quickly and cost-effectively
treatment, replacement parts disassemble
handling,and assemble
bushing the defective
reassembling, RIP
post-
valve side
treatment andbushing
testing.and
Usingits the
composite hollow
field repair insulator,
device, a totalasofwell as accurately
75 bushings control the force
with overheating and
hidden
distance
defects in required to disassemble
copper–aluminum and install
transition jointsthe
in conductive
the State Gridtube Corporation's
with the help of the assisting
system robot
of ±500kV
and laser
Tuanlin, pointer.Baoji, Mujia and Yimin converter stations are repaired on site. All the 75 bushings
Fengjing,
The procedure
have the same structure of field
as therepairing
bushing for abnormal
shown copper–aluminum
in Figure conductive
1. In addition, when tube running
they were transition
joints on defective bushings includes pre-treatment, bushing and repair
under rated load current, it was found through infrared accurate temperature measurement that device positioning, top
cover
the removal,
hottest defect
spot of inspection and
the composite treatment,
hollow replacement
insulators was locatedpartsone
handling, bushing
third of reassembling,
the distance from
post-treatment and testing. Using the field repair device, a total
the air-side terminal, corresponding to the position of copper–aluminum conductive of 75 bushings with overheating
tube
transition joint inside these bushings. Before field repair, in some of the 75 bushings,kV
hidden defects in copper–aluminum transition joints in the State Grid Corporation’s system of ±500
Tuanlin, Fengjing, Baoji, Mujia and Yimin converter stations are repaired on site. All the 75 bushings
decomposition gas SO2 caused by micro-discharge under combined heat and electricity had been
Energies 2019, 12, 4303 11 of 13

have the same structure as the bushing shown in Figure 1. In addition, when they were running
under rated load current, it was found through infrared accurate temperature measurement that the
hottest spot of the composite hollow insulators was located one third of the distance from the air-side
terminal, corresponding to the position of copper–aluminum conductive tube transition joint inside
these bushings. Before field repair, in some of the 75 bushings, decomposition gas SO2 caused by
micro-discharge under combined heat and electricity had been detected, which is more than 50 µL/L.
After the field repair, the main insulation resistance, the capacitance, the dielectric loss factor, the
content of SO2 , the SF6 leakage rate of the repaired bushing, as well as dc resistance together with
converter transformer winding have been tested and fully meet the operational requirement. All these
repaired RIP valve side bushings are now in stable operation.

6. Conclusion
In this paper, the characteristics of a RIP valve side bushing breakdown failure caused by an
abnormal contact at the copper–aluminum conductive tube transition joint is analyzed, and then
according to these analysis, a method of diagnosing four typical internal breakdown failures is proposed.
Meanwhile defective bushings of the same type are repaired by using a field repair devices, drawing
the following conclusions:

(1). In a converter station with structure of 12-pulse valves, when any one of 12 valve side bushings
breaks down, the position of the fault current entering the earth and the location of related failed
bushing can be accurately diagnosed by the characteristics of all valve side currents in Y/Y and
Y/D converter transformers, the magnitude of current in the Pole line and neutral line, as well as
the opening and closing status of each converter valve.
(2). Based on the analysis of capacitance, insulation resistance, SF6 decomposition gas, external
air-side arcing trace on a failed RIP valve side bushing, as well as the DGA result of the related
converter transformer oil, the type of the breakdown failure can be diagnosed, including flashover
outside the air-side of the composite hollow insulator, axial flashover along the RIP condenser/SF6
interface, radial puncture inside the RIP condenser, and oil-side puncture from conductive tube
to the bushing turret.
(3). For the valve side bushing with abnormal contact resistance at the copper–aluminum transition
joint, by applying the total resistance loss of all harmonic current resistances at the area of the
copper–aluminum conductive joint, the finite element temperature simulation can be used to
obtain the temperature values inside and outside the bushing under different load current. Thus
the safety operation current of the defective bushing can be determined.
(4). When repairing and replacing components of the this abnormal contact resistance bushings
on-site, it is necessary to accurately control the installation force, the installation angle, and
installation distance. The special field repair device with laser pointer and power assisting robot
can complete this complex and difficult task.

The transition joint of two conductive tubes is the weak point of RIP valve side bushing. When
the contact resistance increases, long-term overheating can be developed into a serious breakdown
failure. There are many researches on the influence of metal particles on the flashover properties of
solid insulation, but rarely studying on insulating carbonized decomposition particles. Thus when the
RIP condenser/SF6 interface is attached with the insulation carbonized decomposition particles, axial
flashover mechanism needs further study.

Author Contributions: H.T. contributed to the conception of the study, wrote the manuscript. X.L. and J.D.
performed the data analyses and made corrections for the review. M.C. simulated and analysis the temperature
distribution on defective bushing. G.W. helped perform the analysis with constructive discussions.
Funding: This work was supported by the Science and Technology Project of State Grid Corporation of China
(GYB17201600207).
Conflicts of Interest: The authors declare no conflict of interest.
Energies 2019, 12, 4303 12 of 13

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